Manufacture of a wall



Dec 20, 1960 R. DORSETT MANUFACTURE OF A WALL Filed Aug. 24, 1955 FIG. 2

FIG. I

INVENTOR ROSCOE DORSETT HIS ATTORNEY States Patent 0. Tree 2,964,800 MANUFACTURE-oak WALL RoscoeDorsett, 551 WestwoodAve, Dayton, Ohio i ileami z4,'19s's,sr. No.'sso,zss

1 Claim. (c1. -18-'60) Buildin' gs' with eencrete "or Ia'asenr walls have been Also these walls of the wall.

Those who are acquainted with chemicals and metals know that most metals are subject to chemical and elect-rolytic attack. Aluminum foil used in the construction of masonry and concrete buildings is subjected to attack by the elements of concrete and masonry materials.

All who have knowledge in the art of building know that it is desirable to provide an air space in the wall members. They also know that because of the porosity of concrete it is desired that a moisture barrier be provided to prevent moisture passing through the wall. They are aware of the need of a wall that resists the passing of heat. They know the value of providing a design that will improve the appearance of the wall. Heretofore walls have not incorporated these functions- An object of this invention is to provide an improved method for constructing concrete walls in which one or more continuous air spaces exist, the air space being lined with a thin sheet or foil of metal.

Another object of this invention is to provide a means of constructing concrete walls having an inner and an outer member, the outer member being either plain, or

having an imprinted design, and there being a single or plurality of walls of concrete or other material spaced between the inner and outer members.

Another object of this invention is to provide a thin metal sheet or foil moisture barrier and heat reflector, having one side coated with asphaltum or other suitable material not subject to chemical attack by elements of concrete upon which a layer of sand or other material to which mortar or concrete will adhere has been applied.

Another object of this invention is to provide a means of lining cellular wall air spaces with metal foil moisture barrier and heat reflector.

Other advantages and objects inhere in the construction of parts and mode of operation. From the following description the objects and advantages shall become more apparent.

In the drawings:

Figure 1 is a fragmentary side elevational view of a section of wall made according to this invention.

Figure 2 is a horizontal cross-section of Figure 1.

Figure 3 is a curvilineal view of a sheet of metal foil prepared according to this invention with a coating of asphaltum and a layer of sand adhering to the asphaltum.

Figure 4 is an isometric perspective view of a section of matrix made according to this invention.

Referring to the drawings in detail:

In the construction of poured concrete wall members, form members 5 and 6 of any suitable construction covered by a rubberr'natrix '2 which may be held along 2,964,806 patented 20, 9

maybe'u'se d. Forin members 1 "and '7ofany suitable "oiistruction may *als'ob'e u's'ed. Such mold construction be of any character to .p'ermit'the metal 'foil '4 to be 'rna'ihtained i'n flat condition against themold or plywood "5"a'nd"to"permitunset concrete to be placed and bernaintairied infiat form against a layer of relatively small .particles adherent to both the concrete "and the asphaltum on said foil'4'until the concrete sets to provide a conci'ete wall member-or panel 3 with 'a metal foil face 4,

which may be produced in any manner for a building.

The wall member 3 may be fere'cted as a wall for a building under any conditions and many manner desired.

Fniembers 1a'nd6 of the form members maysupport' any smooth "surface opposite layers of material, such as plywood'5 and 7 to permit the "concrete 3 to be made as'a jflat' member for a building. If desired, the plywood surface Z may 'be used injb'are condition or it may be the inner face of'theplyw'ood 7. h

The matrix Z'may be made of any suitablematerial such as rubber and is placed in position against and secured to the inside surface of the plywood 7 in a manner that will permit the removal of the form from the concrete wall member without removing the matrix. This can be accomplished by any one of a number of ways. A simple way of installing the matrix is to install metal eyelets near the top edge of the matrix through which pins may be driven into the form. The matrix may be suspended in its proper position for any required distance.

The moisture barrier and heat reflector 4 is placed in contact with the plywood 5.

The sheet of metal foil 4 in Figure 3 has been prepared according to this invention. The reflective side is indicated by the number 11. The number 10 indicates the opposite side of the sheet of metal foil which has been prepared in a manner that facilitates its adherance to wet concrete or other similar wet materials, such as, for example, gypsum and plaster.

The moisture barrier and heat reflector can be made by any one of several methods. A simple method is to spread the sheet of metal on a fiat surface and apply by brush, spraying, pouring, or other means of application, a coating of asphaltum or other suitable material in liquid state. A layer of sand or other material to which concrete will adhere is now spread over the layer of asphaltum. The sand becomes imbedded in the asphaltum and is bound thereby to the metal sheet. The sand coming in contact'with the wet concrete becomes an element of the concrete through the action of the cement in the concrete. The coating of asphaltum also prevents the metal coming in contact with the concrete, thereby protesting the metal from chemical and/or electrolytic att-ack' by the elements of the concrete. The asphaltum backing may be strengthened by the admixture of mineral and/or other fibrous material.

Having assembled the form members 1, 5, 6 and 7, having positioned the matrix 2 in place on plywood 7, and having placed the moisture barrier and heat reflector 10, 11 in place on plywood 5, the form or mold is ready for filling with concrete 3 or similar material.

The form members being assembled and arranged in their proper place, the concrete is then poured into the space provided by the forms. The wet concrete coming in contact with the sand or other material imbedded in the asphaltum backing on the moisture barrier and heat reflector becomes a part of the concrete.

After waiting for a period of time for the concrete to become suificiently solidified, the forms are removed.

being smooth, or having indentations, beads or grooves may hold to the solidified concrete after the form members have been removed. However, a reasonable force applied in a manner to pull the matrix from the concrete will not afiect the release, and the wall will retain the design, shape or imprint of the matrix.

The concrete wall member is now complete with mois- :ture barrier and heat reflector having become an integral member. .While the specific method now preferred has been disclosed as required by statute, such method may be modi- Ified in any manner coming within the scope of the claimed method which follows.

Having thus described my invention, I claim:

The method of manufacture of a wall for a building comprising: coating a flexible metal foil with asphaltum; coating said asphaltum with a layer of relatively small solid particles adherent to both concrete and said asphaltum; maintaining said foil in flat condition against a the form of a flat wall against said particles until said concrete sets; and removing said wall mold to provide a concrete wall with a metal foil face.

References Cited in the file of this patent UNITED STATES PATENTS 1,175,376 Patee Mar. 14, 1916 1,830,397 Kleitz Q. -Q' Nov. 3, 1931 1,841,581 Garrett Jan. 19, 1932 1,862,544 McWane June 14, 1932 1,898,864 1Young' Feb. 21,- 1933 1,915,896 .Maul g June 27, 1933 1,917,062 Reinhard July 4, 1933 2,059,520 I-' I'a1rshb erger- Nov. 3, 1936 2,149,732 Groff Mar. 7, 1939 2,210,960 St. Pierre Aug. 13, 1940 2,371,124 Austin et a1 Mar. 13, 1945 2,422,461 Arquette June 17, 1947 2,424,353 Essig July 22, 1947 2,427,780 Haines Sept. 23, 1947 j 2,441,695 Feagin et al. May 18, 1948 2,444,533 Richardson July 6, 1948 2,558,632 Trozmuller June 26, 1951 2,595,142 Herck Apr. 29, 1952 2,739,881 Kepple Mar. 27, 

